Method for Fabricating Composite Structures Using Combined Resin Film and Dry Fabric

ABSTRACT

A method may include placing a dry fabric over a tool; pressing a first resin film over the dry fabric while the dry fabric is draped over the tool to create an outer layer of the laminate composite structural component; repeating the placing and pressing process until a desired thickness of the outer layer is achieved; compressing a second resin film and a dry fiber fabric between two rollers to tack the second resin film to the dry fiber fabric to create a resin-fabric sheet comprising a resin film layer and an dry fiber fabric layer; cutting the resin-fabric sheet to a pre-determined shape to create at least one resin-fabric preform; and draping a first resin-fabric preform over at least a portion of the outer layer, wherein one or more edges of the first resin-fabric preform overlap the outer layer to create an internal edge.

FIELD

The present disclosure relates to the fabrication of laminate compositestructures using the process of resin film infusion, and moreparticularly to preparation and lay up of the multiple dry fabric andresin film preforms into a laminate structure prior to curing.

BACKGROUND

Resin film infusion is a known process for manufacturing laminatecomposite structures which uses, as its basic feedstock material, sheetsof resin film and dry fabric. The resin film and the dry fabric sheetsare laid up in alternating layers onto or into a forming tool, and thenheated for consolidation and then curing. During heating, the resin filmfirst melts, or undergoes a significant viscosity reduction, and wetsthe adjoining fibers substantially completely coating or encapsulatingthem. The resin and now-wetted fibers then cure into a single solidstructure.

Resin film infusion is selected as an effective and efficient processfor forming many large composite structures. But, when a laminatestructure requires internal laminate edges (where the resin and dryfabric sheets have an edge that is overlaid on a prior layer, and willnot form part of a perimeter of the part) resin film infusion can resultin a part with degraded material properties because of the propensity ofthe dry fabric sheet edges to fray, and the difficulty in preciselyaligning edges of the resin film sheet with edges of the dry fabricsheet.

SUMMARY

Methods of creating composite structures are provided. A method forcreating a laminate composite structural component may comprise: placinga dry fabric over a tool, the tool comprising a contour of at least aportion of the laminate composite structural component; pressing a firstresin film over the dry fabric while the dry fabric is draped over thetool to create an outer layer of the laminate composite structuralcomponent; repeating the placing and pressing process until a desiredthickness of the outer layer is achieved; compressing a second resinfilm and a dry fiber fabric between two rollers to tack the second resinfilm to the dry fiber fabric to create a resin-fabric sheet comprising aresin film layer and an dry fiber fabric layer; cutting the resin-fabricsheet to a pre-determined shape to create at least one resin-fabricpreform; and draping a first resin-fabric preform over at least aportion of the outer layer, wherein one or more edges of the firstresin-fabric preform overlap the outer layer to create an internal edge.

In various embodiments, the method may further comprise, rolling arelease poly-film over the resin-fabric sheet, the second resin filmlocated between the release poly-film and the dry fiber fabric. Thetacking may be performed at room temperature. The dry fiber fabric maycomprise a carbon fiber, non-crimp fabric. The method may furthercomprise, setting a mandrel over the outer layer, wherein the firstresin fabric preform is placed over at least a portion of the mandrel tocreate a feature. The method may further comprise, draping a secondresin-fabric preform over at least a portion of the first resin-fabricpreform, wherein one or more edges of the second resin-fabric preformoverlap the internal edge.

A method for creating a fan cowl with a hollow hat stiffener maycomprise: pressing a resin film between a non-crimp fabric (NCF) and arelease poly-film to tack the resin film to the NCF and the releasepoly-film and to create a resin-fabric sheet comprising at least a resinfilm layer and an NCF layer; cutting the resin-fabric sheet to apre-determined shape to create at least one of a first resin-fabricpreform, a second resin-fabric preform, and a third resin-fabricpreform; draping at least the first resin-fabric preform over a tool tocreate an outer layer of the fan cowl; setting a mandrel over the outerlayer; and draping the second resin-fabric preform over at least aportion of the mandrel and at least a portion of the first resin-fabricpreform to form the hollow hat stiffener having a geometry similar to ashape of the mandrel.

In various embodiments, the method may further comprise, draping thethird resin-fabric preform over at least a portion of the secondresin-fabric preform to create a desired thickness of the hollow hatstiffener. The method may further comprise, heating the firstresin-fabric preform, the second resin-fabric preform, and the thirdresin-fabric preform to cure the first resin-fabric preform, the secondresin-fabric preform, and the third resin-fabric preform to create thefan cowl. The method may further comprise, removing the mandrel from thefan cowl. In response to the first resin-fabric preform being drapedover the tool with the resin film layer contacting the tool, the resinfilm layer of the second resin-fabric preform may be adjacent to the NCFlayer of the first resin-fabric preform. In response to the firstresin-fabric preform being draped over the tool with the NCF layercontacting the tool, the NCF layer of the second resin-fabric preformmay be adjacent to the resin film layer of the first resin-fabricpreform. The pressing may be performed at a room temperature.

A method may comprise: storing a resin film in a cold storageenvironment; storing a non-crimp fabric (NCF) at a room temperature;removing the resin film from the cold storage environment to increase atemperature of the resin film to the room temperature; tacking the resinfilm to the non-crimp fabric (NCF) to create a resin-fabric sheetcomprising a resin film layer and an NCF layer; cutting the resin-fabricsheet to a pre-determined shape to create a resin-fabric preform; anddraping the resin-fabric preform over a contoured surface.

In various embodiments, the NCF may comprise a non-woven carbon fiberfabric. The tacking the resin film to the NCF may include using at leastone roller to press the resin film and the NCF together. The method mayfurther comprise, applying a release poly-film to the resin-fabric sheetsuch that the resin film layer is located between the release poly-filmand the NCF layer, the release poly-film configured to at leastpartially cover the resin film layer. The method may further comprise,rolling the resin-fabric sheet onto a roller. The method may furthercomprise: applying a vacuum to at least a portion of the resin-fabricpreform to pull the resin-fabric preform against the contoured surface;and baking the resin-fabric preform. The tacking may be performed at theroom temperature.

The foregoing features, elements, steps, or methods may be combined invarious combinations without exclusivity, unless expressly indicatedherein otherwise. These features, elements, steps, or methods as well asthe operation of the disclosed embodiments will become more apparent inlight of the following description and accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The subject matter of the present disclosure is particularly pointed outand distinctly claimed in the concluding portion of the specification. Amore complete understanding of the present disclosure, however, may bestbe obtained by referring to the detailed description and claims whenconsidered in connection with the drawing figures, wherein like numeralsdenote like elements.

FIG. 1 illustrates a perspective view of a hollow hat fan cowl, inaccordance with various embodiments;

FIG. 2 illustrates a combiner for combining non-crimp fabric to resinfilm to create a resin-fabric sheet, in accordance with variousembodiments;

FIG. 3 illustrates the resin fabric sheet of FIG. 2, in accordance withvarious embodiments;

FIG. 4 illustrates a process of laying up a composite structure, inaccordance with various embodiments;

FIG. 5 illustrates a method, in accordance with various embodiments;

FIG. 6 illustrates a method for creating a fan cowl, in accordance withvarious embodiments;

FIG. 7 illustrates a method for creating a fan cowl with hollow hatstiffeners, in accordance with various embodiments;

FIG. 8 illustrates resin-fabric preforms cut from a resin-fabric sheet,in accordance with various embodiments; and

FIG. 9 illustrates a process of laying up a composite structure, inaccordance with various embodiments.

DETAILED DESCRIPTION

The detailed description of exemplary embodiments herein makes referenceto the accompanying drawings, which show exemplary embodiments by way ofillustration. While these exemplary embodiments are described insufficient detail to enable those skilled in the art to practice theinventions, it should be understood that other embodiments may berealized and that logical changes and adaptations in design andconstruction may be made in accordance with this invention and theteachings herein. Thus, the detailed description herein is presented forpurposes of illustration only and not of limitation. The scope of theinvention is defined by the appended claims. For example, the stepsrecited in any of the method or process descriptions may be executed inany order and are not necessarily limited to the order presented.Furthermore, any reference to singular includes plural embodiments, andany reference to more than one component or step may include a singularembodiment or step. Also, any reference to attached, fixed, connected orthe like may include permanent, removable, temporary, partial, fulland/or any other possible attachment option. Additionally, any referenceto without contact (or similar phrases) may also include reduced contactor minimal contact. Surface shading and/or crosshatching lines may beused throughout the figures to denote different parts, but notnecessarily to denote the same or different materials.

As used herein the term “prepreg” may refer to fibrous structures, withglass fibers, carbon fibers, aramid fibers, and/or the like,pre-impregnated with an uncured or at least partially uncured matrixmaterial, such as a resin, where the substantial majority of fibers aregenerally completely encased in the matrix material.

As used herein the term “dry fabric” may refer to a fabric sheet made upof dry fibers (e.g., carbon fibers, glass fibers, and/or the like) thathave not been impregnated with resin or matrix material.

As used herein the term “non-crimp fabric” or “NCF” may refer to a typeof dry fabric made of uni-directional, non-woven, generally straightfibers (e.g., carbon fibers, glass fibers and/or the like).

As used herein the term “resin film” or “RF” may refer to a film orsheet of semi-solid, uncured or at least partially uncured resin. The RFmay generally be supplied on a release paper and configured to beinterleaved with layers of dry fabric during a film infusion process.

As used herein the term “drapability” may refer to the ability tosmoothly drape a continuous sheet, or the like, over a contouredsurface, especially a surface contoured in multiple directions. Statedanother way, “drapability” may refer to how closely such structure takeson the shape of the surface over which it is being draped or placedwithout wrinkling or other defects.

Manufacturing laminated composite structures, such as those now commonlyused in aerospace structures, can be time consuming and expensive. Forexample, a layup process for creating a laminated composite structuremay comprise forming and cutting many thin composite layers and thenlaying them by hand onto or into a forming tool before curing. The layupprocess typically constitutes a large portion of the total labor hoursneeded to form a part, and is also a potential source of many qualityproblems due to its manual nature and its reliance on individualtechnician skill and performance.

Certain materials used in creating laminated composite structures arerelatively expensive. Prepreg material is one example of a relativelyexpensive material. It constitutes a fiber fabric (woven or nonwoven)that has been pre-impregnated with an uncured or partially cured resin.Typically, the highest quality prepreg materials must be stored at lowtemperatures to prevent the resin from curing before a part is laid-up.The low temperature storage equipment adds costs, and even at lowtemperatures a high-quality prepreg typically has a limited shelf lifebefore it must be cured, otherwise the performance of the end structureis compromised. Thus, even when stored at low temperatures, some prepregis typically scrapped and wasted because it is not used within itsshelf-life, adding to the operational cost of producing parts withprepregs.

Another disadvantage of prepregs is their lack of drapability. Becausethe individual fibers are fairly tightly bound together by the uncured,but viscous and very tacky resin, the fibers cannot easily sliderelative to one another, and therefore the prepreg sheet does notstretch or compress easily. This can make draping large prepreg sheetsover tool surfaces curved in multiple directions very difficult.

To address these difficulties, some laminate composite parts are madeusing a resin film infusion process which typically constitutes sheetsof dry fabric (woven or nonwoven) layered alternately with separatelylaid up sheets of resin film, which are then heated for consolidationand then curing. During heating, the resin film first melts, orundergoes a significant viscosity reduction, and wets the adjoiningfibers substantially completely coating or encapsulating them. The resinand now-wetted fibers then cure into a single solid structure. Such aresin film infusion process utilizes a dry fiber fabric feedstock (whichis typically much more expensive than the resin film) that has apractically unlimited shelf life because it is kept separate from theresin film which has a limited shelf life, resulting in less waste ofthe fiber fabric and improved operational costs. Also, the dry fiberfabric and thin resin film sheets generally have better drapabilityproperties than prepregs. As already known to those of ordinary skill inthis art, these advantages make resin film infusion processes attractivefor making many different parts.

A disadvantage of resin film infusion is that the dry fabric can bedifficult to handle. Especially in the case of the nonwoven non-crimpfabrics (NCF), the dry fibers in the fabric can fray easily at the sheetedges, resulting in uneven fiber distribution and degraded materialproperties after curing. This risk is addressed by making the layuplarger than the final part, and then after curing by trimming theperimeter of the part where fraying may have occurred. Any frayed edgesare trimmed off, leaving an edge where the fiber distribution is moreconsistent. While this method effectively addresses fraying of the dryfabric on external edges of the part, it does not work for internaledges. Some layups are designed with detail pieces of fabric laid upinside of a larger field, where some or all of the edges of the detailsheet of fabric are not external edges, but rather are overlaid onto thelarger sheets of fabric and resin film underneath. Such an internal edgecannot be trimmed after curing, and without trimming the edge of thesheet laid up on the tool becomes the “net edge” after curing.

In addition to the risk of fraying, there is also a related risk of thedry fabric and the resin film sheet edges not being perfectly alignedwhen laid up by the technician. Any misalignment of the two sheets orlayers on an external edge can be trimmed away as described above, butinternal edges cannot be trimmed after curing to solve this problem.

As a solution to the above problems previously inherent with resin filminfusion processes, the inventors have developed a method of tackingtogether dry fiber fabric and resin film feedstocks to one another,before trimming into sheets and lay up on the forming tool. The twolayers are merely loosely tacked together, and remain separate anddistinct layers. The combined material thus maintains most of theadvantageous drapability properties of the dry fabric and resin filmused in a resin film infusion process. The combined material alsoadvantageously controls fiber fraying at the edges, as the tackiness ofthe resin film tends to hold the fibers in place during handling and layup. Also, if trimming into a desired sheet shape for lay up is performedafter the resin film and dry fiber fabric are tacked together, then thetwo layers stay tacked together and the edges of each layer remainperfectly aligned during handling and after lay up on the forming tool.Use of this tacked-together, pre-combined resin film and dry fiberfeedstock has been found to significantly increase the quality of aresin film infusion production process, and to significantly reduce thelabor hours and resultant costs of the process.

With reference to FIG. 1, an aerostructure article, illustrated as fancowl 10 is provided, in accordance with various embodiments. Althoughillustrated as a fan cowl 10, it is contemplated herein that the methodof creating a composite structure, as described herein, may be used onany composite structure. Fan cowl 10 may be a co-cured compositestructure having a unitary skin 12 and reinforcing hat sections (alsoreferred to herein as hollow hat stiffeners) 14, 16, and 18. Reinforcinghat sections 14, 16, and 18 may be circumferentially extending andaxially spaced apart sections. Reinforcing hat sections 14, 16, and 18may comprise hollow hat stiffeners. The fan cowl 10 is shown asgenerally arcuate in shape, as illustrated in FIG. 1, but the use of thedisclosed methods may extend to other shapes and applications. Invarious embodiments, longeron members 30 may be attached to the ends offan cowl 10. Longeron members 30 may be used for hinging the fan cowl toanother structure or for latching two such fan cowls together or forother desired purposes.

With reference to FIG. 5, a method 500 is provided, in accordance withvarious embodiments. Method 500 may be used in preparation for andduring a composite layup process. With reference to FIG. 6, a method 600for creating a fan cowl is provided, in accordance with variousembodiments. Method 600 may be used for creating fan cowls with hollowhat stiffeners. With reference to FIG. 7, a method 700 for creating afan cowl with hollow hat stiffeners is provided, in accordance withvarious embodiments. Method 700 may allow for on-demand combination ofresin-film and non-crimp fabric in preparation for forming a fan cowl orother composite structures. With reference to FIG. 5, FIG. 6, and FIG.7, the steps to method 500, method 600 and method 700, respectively, areprovided herein.

With reference to FIG. 2, a combiner 200 is illustrated, in accordancewith various embodiments. Combiner 200 may be for combining resin film(RF) 222 to a dry fabric, such as non-crimp fabric (NCF) 220. Combiner200 may include a body 230 attached to one or more rolls for supplyingor catching material. Roll 210 may supply NCF 220. Roll 208 may supplyRF 222. Roll 202 may supply a release poly-film 228. Roll 206 may catchrelease paper (also referred to herein as a first release paper) 224.Roll 204 may catch release paper (also referred to herein as a secondrelease paper) 226. Release poly-film 228 may comprise a drapablematerial. In various embodiments, release poly-film 228 may comprise apolyurethane film, a polyethylene film, a polypropylene film, or anyother suitable poly material which is drapable. In various embodiments,first release paper 224 and second release paper 226 may comprise a polymaterial, a paper material, or any other suitable material. Firstrelease paper 224 may be removed from RF 222. Second release paper 226may be removed from RF 222.

With momentary reference to FIG. 5, NCF 220 may be tacked to RF 222 byfirst roller 212 and second roller 214 to combine NCF 220 and RF 222into a single resin-fabric sheet 232 (see step 504). With momentaryreference to FIG. 6, NCF 220 and RF 222 may be compressed or pressedbetween first roller 212 and second roller 214 to combine NCF 220 and RF222 into the single sheet (see step 604). Such combination may beperformed at room temperature. However, in various embodiments, suchcombination may be performed with additional heat applied to increasethe tackiness of RF 222. Then, with momentary reference to FIG. 6)release poly-film 228 may be rolled or otherwise applied over RF 222(see step 605) to protect and cover RF 222 until it is ready for use.Release poly-film 228 may be compressed or pressed between third roller216 and table 218 for tacking release poly-film 228 to RF 222. Statedanother way, with momentary reference to FIG. 7, RF 222 may be pressedbetween NCF 220 and release poly-film 228 (see step 701).

In response to RF 222 being tacked onto NCF 220, as described herein, RF222 may hold the fibers of NCF 220 in place to prevent NCF 220 fromfraying during a cutting process. Furthermore, the tackiness of RF 222may prevent fibers from fraying at the edges of NCF 220 during handlingand lay up.

In various embodiments, resin-fabric sheet 232 may be immediately cutinto preforms after being formed. However, resin-fabric sheet 232 may berolled over itself or onto a roller for storage or transport beforebeing cut into preforms.

With reference to FIG. 3, a resin-fabric sheet 232 is illustrated havinga release poly-film 228, in accordance with various embodiments.Resin-fabric sheet 232 may comprise NCF 220 (also referred to herein asan NCF layer), RF 222 (also referred to herein as a resin film layer),and, in various embodiments, release poly-film 228 (also referred toherein as a release poly-film layer). NCF 220 and RF 222 may comprisetwo distinct layers tacked together, without any (or minimal) wetting orcoating of the fibers of NCF 220. Thus, the fibers of NCF 220 may remainsubstantially dry without resin.

With reference now to FIG. 3 and FIG. 5, in various embodiments, it maybe desirable to store resin film (RF) 222 in a refrigerator or freezer(i.e., a cold storage environment) to extend the shelf-life of the RF222 (see step 501). Non-crimp fabric (NCF) 220 may be stored at roomtemperature (see step 502). Thus, NCF 220 may be stored separately fromRF 222 until time of use. Thus, at time of use, RF 222 may be removedfrom the cold storage environment (see step 503) to increase thetemperature of the resin film to the room temperature. Accordingly,storing NCF 220 and RF 222 separately until time of use may free upstorage space in the cold storage environment, decreasing the requiredvolume of storage space in the cold storage environment.

With reference to FIG. 8, resin-fabric preforms 826, 828, and 830 cutfrom resin-fabric sheet 232 are illustrated, in accordance with variousembodiments. With momentary reference to FIGS. 5 and 6, resin-fabricpreform (also referred to herein as a first resin-fabric preform) 830,resin-fabric preform (also referred to herein as a second resin-fabricpreform) 828, and resin-fabric preform (also referred to herein as athird resin-fabric preform) 826 may be cut from resin-fabric sheet 232(see step 505 and step 606) via any suitable method such as via a knifeor the like, for example. First resin-fabric preform 830, secondresin-fabric preform 828, and third resin-fabric preform 826 may be cutfrom resin-fabric sheet 232 before draping over a tool for forming intoa composite structure. First resin-fabric preform 830, secondresin-fabric preform 828, and third resin-fabric preform 826 maycomprise pre-determined geometries or shapes. In various embodiments,any one of resin-fabric preform 826, 828, and/or 830 may be draped overa contoured surface (see step 506) as described herein.

With reference to FIG. 4 and FIG. 7 a process of creating a compositestructure 800 is illustrated, in accordance with various embodiments. Invarious embodiments, first resin-fabric preform 830 may be draped orplaced over tool 410 (see step 703). In various embodiments, tool 410may have a shape complementary to the shape of a fan cowl. Firstresin-fabric preform 830 may create an outer layer of a compositestructure. Although illustrated as a single layer, it is well known to aperson having ordinary skill in the art that the outer layer of thecomposite structure may comprise multiple layers (i.e., multiple layersof resin-fabric preform 803) in order to create a desired thickness.FIG. 4 illustrates a single layer comprising the outer layer but it iscontemplated that the outer layer may comprise multiple layers. In thisregard, first resin-fabric preform 830 may, in fact, comprise multipleresin-fabric preforms. Furthermore, multiple resin-fabric preforms maybe used to create a desired width of the outer layer. For example, aroll of resin-fabric preform may not be as wide as a desired width of afan cowl. Thus, first resin-fabric preform 830 may comprise multipleresin-fabric preforms overlapped to create a desired width, in additionto the desired thickness. With momentary reference to FIG. 1, firstresin-fabric preform 830 may form outer layer 20 of fan cowl 10. Mandrel430 may be placed over first resin-fabric preform 830 (see step 704). Invarious embodiments, with further reference to FIG. 6, secondresin-fabric preform 828 may be draped over mandrel 430 and over aportion of first resin-fabric preform 830 to create a feature of thecomposite structure (see step 705 and step 608) having a geometrysimilar to a shape of mandrel 430. In various embodiments, secondresin-fabric preform 828 may comprise an internal edge 450. In variousembodiments, internal edge 450 may be an edge of a dry fabric sheetlocated inward of the external or outside edges of a part. For example,internal edge 450 is located inward of external edge 452. Mandrel 430may comprise a contoured surface 432. Next, third resin-fabric preform826 may be draped over at least a portion of second resin-fabric preform828 to create a desired thickness 440 (see step 706) of the feature. Invarious embodiments, third resin-fabric preform 826 may overlap internaledge 450. In various embodiments, the feature may comprise a hollow hatstiffener.

In various embodiments, after a layup process is completed, a curingprocess may be performed on the preforms to consolidate the preformsinto a unitary composite structure. The curing process may be performedby encapsulating the preforms between a vacuum bag and the tool andsucking air out of the bag. Thus, vacuum may be applied to the preforms.The curing process may further include heating the layup in an autoclavein a resin film infusion process as previously mentioned herein. Invarious embodiments, method 500, 600, and/or 700 (see FIGS. 5, 6 and/or7, respectively) may include the curing process. The baking may beperformed at baking temperatures of between one hundred degrees Celsius(212° F.) and three hundred degrees Celsius (572° F.), for example. Thebaking may be performed for any suitable duration such as between 20minutes and 50 hours, for example. In various embodiments, baking may beperformed using ramped temperatures or in cycles.

Next, with continuing reference to FIG. 4, mandrel 430 may be removedfrom between first resin-fabric preform 830 and second resin-fabricpreform 828. With momentary reference to FIG. 1, the resulting compositestructure 800 may comprise a fan cowl 10 having one or more reinforcinghat sections 14, 16, and/or 18 as illustrated in FIG. 1.

With reference to FIG. 4, in response to the first resin-fabric preform830 being draped over tool 410 with the resin film layer 422 contactingtool 410, as illustrated in FIG. 4, the resin film layer 426 of thesecond resin-fabric preform 828 is placed adjacent to the NCF layer 420of the first resin-fabric preform 830. However, in various embodiments,in response to the first resin-fabric preform 830 being draped over tool410 with the NCF layer 420 contacting tool 410, the NCF layer 424 of thesecond resin-fabric preform 828 is adjacent to the resin film layer 422of the first resin-fabric preform 830.

With reference to FIG. 9, a process for laying up a composite structureis illustrated, in accordance with various embodiments. With furtherreference to FIG. 6, a dry fabric 920 may be placed over tool 410 (seestep 601). A resin film (also referred to herein as a first resin film)922 may be placed and pressed over dry fabric 920 while dry fabric 920is draped over the tool 410, thus creating an outer layer 924 (see step602). Outer layer 924 may be similar to outer layer 20 (see FIG. 1). Invarious embodiments, this process may be repeated to increase thethickness 930 of outer layer 924 to a desired thickness (see step 603).The outer edges 940 of outer layer 924 may be trimmed as illustrated inFIG. 9. Mandrel 430 may be placed over outer layer 924 (see step 607).In various embodiments, resin-film sheets may be placed over mandrel 930and possibly other location of outer layer 924 as described in to FIG.4. The outer edges 940 may be trimmed before and/or after the outerlayer 924 has been cured in an auto clave.

Benefits, other advantages, and solutions to problems have beendescribed herein with regard to specific embodiments. Furthermore, theconnecting lines shown in the various figures contained herein areintended to represent exemplary functional relationships and/or physicalcouplings between the various elements. It should be noted that manyalternative or additional functional relationships or physicalconnections may be present in a practical system. However, the benefits,advantages, solutions to problems, and any elements that may cause anybenefit, advantage, or solution to occur or become more pronounced arenot to be construed as critical, required, or essential features orelements of the inventions. The scope of the inventions is accordinglyto be limited by nothing other than the appended claims, in whichreference to an element in the singular is not intended to mean “one andonly one” unless explicitly so stated, but rather “one or more.”Moreover, where a phrase similar to “at least one of A, B, or C” is usedin the claims, it is intended that the phrase be interpreted to meanthat A alone may be present in an embodiment, B alone may be present inan embodiment, C alone may be present in an embodiment, or that anycombination of the elements A, B and C may be present in a singleembodiment; for example, A and B, A and C, B and C, or A and B and C.

Systems, methods and apparatus are provided herein. In the detaileddescription herein, references to “various embodiments”, “oneembodiment”, “an embodiment”, “an example embodiment”, etc., indicatethat the embodiment described may include a particular feature,structure, or characteristic, but every embodiment may not necessarilyinclude the particular feature, structure, or characteristic. Moreover,such phrases are not necessarily referring to the same embodiment.Further, when a particular feature, structure, or characteristic isdescribed in connection with an embodiment, it is submitted that it iswithin the knowledge of one skilled in the art to affect such feature,structure, or characteristic in connection with other embodimentswhether or not explicitly described. After reading the description, itwill be apparent to one skilled in the relevant art(s) how to implementthe disclosure in alternative embodiments.

Furthermore, no element, component, or method step in the presentdisclosure is intended to be dedicated to the public regardless ofwhether the element, component, or method step is explicitly recited inthe claims. No claim element herein is to be construed under theprovisions of 35 U.S.C. 112(f) unless the element is expressly recitedusing the phrase “means for.” As used herein, the terms “comprises”,“comprising”, or any other variation thereof, are intended to cover anon-exclusive inclusion, such that a process, method, article, orapparatus that comprises a list of elements does not include only thoseelements but may include other elements not expressly listed or inherentto such process, method, article, or apparatus.

We claim:
 1. A method for creating a laminate composite structuralcomponent comprising: placing a dry fabric over a tool, the toolcomprising a contour of at least a portion of the laminate compositestructural component; pressing a first resin film over the dry fabricwhile the dry fabric is draped over the tool to create an outer layer ofthe laminate composite structural component; repeating the placing andpressing process until a desired thickness of the outer layer isachieved; compressing a second resin film and a dry fiber fabric betweentwo rollers to tack the second resin film to the dry fiber fabric tocreate a resin-fabric sheet comprising a resin film layer and an dryfiber fabric layer; cutting the resin-fabric sheet to a pre-determinedshape to create at least one resin-fabric preform; and draping a firstresin-fabric preform over at least a portion of the outer layer, whereinone or more edges of the first resin-fabric preform overlap the outerlayer to create an internal edge.
 2. The method of claim 1, furthercomprising, rolling a release poly-film over the resin-fabric sheet, thesecond resin film located between the release poly-film and the dryfiber fabric.
 3. The method of claim 1, wherein the tacking is performedat room temperature.
 4. The method of claim 1, wherein the dry fiberfabric comprises a carbon fiber, non-crimp fabric.
 5. The method ofclaim 1, further comprising, setting a mandrel over the outer layer,wherein the first resin fabric preform is placed over at least a portionof the mandrel to create a feature.
 6. The method of claim 1, furthercomprising, draping a second resin-fabric preform over at least aportion of the first resin-fabric preform, wherein one or more edges ofthe second resin-fabric preform overlap the internal edge.
 7. A methodfor creating a fan cowl with a hollow hat stiffener comprising: pressinga resin film between a non-crimp fabric (NCF) and a release poly-film totack the resin film to the NCF and the release poly-film and to create aresin-fabric sheet comprising at least a resin film layer and an NCFlayer; cutting the resin-fabric sheet to a pre-determined shape tocreate at least one of a first resin-fabric preform, a secondresin-fabric preform, and a third resin-fabric preform; draping at leastthe first resin-fabric preform over a tool to create an outer layer ofthe fan cowl; setting a mandrel over the outer layer; and draping thesecond resin-fabric preform over at least a portion of the mandrel andat least a portion of the first resin-fabric preform to form the hollowhat stiffener having a geometry similar to a shape of the mandrel. 8.The method of claim 7, further comprising, draping the thirdresin-fabric preform over at least a portion of the second resin-fabricpreform to create a desired thickness of the hollow hat stiffener. 9.The method of claim 8, further comprising, heating the firstresin-fabric preform, the second resin-fabric preform, and the thirdresin-fabric preform to cure the first resin-fabric preform, the secondresin-fabric preform, and the third resin-fabric preform to create thefan cowl.
 10. The method of claim 9, further comprising, removing themandrel from the fan cowl.
 11. The method of claim 7, wherein inresponse to the first resin-fabric preform being draped over the toolwith the resin film layer contacting the tool, the resin film layer ofthe second resin-fabric preform is adjacent to the NCF layer of thefirst resin-fabric preform.
 12. The method of claim 7, wherein inresponse to the first resin-fabric preform being draped over the toolwith the NCF layer contacting the tool, the NCF layer of the secondresin-fabric preform is adjacent to the resin film layer of the firstresin-fabric preform.
 13. The method of claim 7, wherein the pressing isperformed at a room temperature.
 14. A method comprising: storing aresin film in a cold storage environment; storing a non-crimp fabric(NCF) at a room temperature; removing the resin film from the coldstorage environment to increase a temperature of the resin film to theroom temperature; tacking the resin film to the non-crimp fabric (NCF)to create a resin-fabric sheet comprising a resin film layer and an NCFlayer; cutting the resin-fabric sheet to a pre-determined shape tocreate a resin-fabric preform; and draping the resin-fabric preform overa contoured surface.
 15. The method of claim 14, wherein the NCFcomprises a non-woven carbon fiber fabric.
 16. The method of claim 14,wherein the tacking the resin film to the NCF includes using at leastone roller to press the resin film and the NCF together.
 17. The methodof claim 14, further comprising, applying a release poly-film to theresin-fabric sheet such that the resin film layer is located between therelease poly-film and the NCF layer, the release poly-film configured toat least partially cover the resin film layer.
 18. The method of claim17, further comprising, rolling the resin-fabric sheet onto a roller.19. The method of claim 14, further comprising: applying a vacuum to atleast a portion of the resin-fabric preform to pull the resin-fabricpreform against the contoured surface; and baking the resin-fabricpreform.
 20. The method of claim 14, wherein the tacking is performed atthe room temperature.